Summary of Contents for Polaris 500

Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

• RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Safety Decals and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

The park/emergency brake lever will supply increased braking, but should be used as an emergency or parking brake only. READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES.

Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

Operator Safety Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow the operating procedures described. •...

Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities.

See page 21 for fuel safety warnings. • Always remove the ignition key when the vehicle is not in use to pre- vent unauthorized use or accidental starting. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800- 342-3764.

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

Operator Safety POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power.

Operator Safety POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention.

Operator Safety POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice.

SAFETY Operator Safety POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition.

Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver's license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are...

Operator Safety Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.

Component Locations Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102. Cab Frame (if Equipped) Console Cargo Box Steering Wheel Storage Box (under driver’s seat)

FEATURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is located on the console. See page 28. Low Gear Reverse (if equipped) Gear Brakes High High Neutral Temperature Gear Gear Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.

FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

Seat Belts Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the RANGER. Passengers under five years of age require special restraints, which are not available with this vehicle. No person under the age of five may ride in the RANGER.

Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse NOTE: Low gear is the primary driving range for the RANGER. High gear is intended for use on hard- packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to Brake increase engine speed. Pedal Spring pressure returns the pedal to the rest position when released.

Switches Light Switch AWD/ Differential Switch Ignition Switch Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

OPERATION Starting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Sit in the driver's seat and fasten the seat belt.

Starting the Engine 8. After the engine starts, push the choke knob in half way. 9. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. 10. Push the choke knob in. Operating the vehicle immediately after starting could cause engine damage.

Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these con- ditions, follow these precautions: 1. Slow down when entering slippery areas. 2.

Driving Safely Driving on a Sidehill (Sidehilling) Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15°...

The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum...

Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Watch for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle.

Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Place the transmission in gear. 2. Engage the park brake. 3. Turn the engine off. 4. Block the rear wheels on the downhill side. A rolling vehicle can cause property damage and serious injury.

Driving Safely Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model RANGER 4X4 RANGER 2X4 Driving with passengers in the cargo box can result in severe injury or...

OPERATION Driving Safely Dumping the Cargo Box Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions.

Driving Safely Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing: Never load more than the recommended vertical tongue weight on the towing bracket.

Differential Operation Modes The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. On 4X4 models, engaging AWD locks the front differential and the rear differential. AWD (4X4) Press the top of the rocker switch to engage All Wheel Drive (AWD).

OPERATION All Wheel Drive (AWD) (4X4 Models) The illuminated amber AWD switch indicates that the vehi- cle is in AWD. When the AWD switch is on, the front gearcase will auto- matically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Fed- eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 121.

Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Have an authorized Polaris dealer perform these services. Improperly performing the procedures marked with a component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W- 40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient tem- perature operation.

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil. Oil Check The oil tank is located under the seat.

Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 106 for the part numbers of Polaris products. Oil Check The fill plug is located at the rear of the vehicle.

Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug.

Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 106 for the part numbers of Polaris products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.

Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants, capacities and torque specifications. See page 106 for the part numbers of Polaris lubrication products. Oil Check The rear gearcase fill plug is on the driver's side of the rear gearcase.

MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.

Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 106 for the part numbers of Polaris prod- ucts. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

Reinstall the cap. NOTE: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your Polaris dealer. CAUTION Overflow Bottle...

Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 52. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.

• Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This PVT system is intended for use on Polaris products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

PVT System PVT Drying There may be some instances when water is ingested into the PVT sys- tem. Use the following instructions to dry it out before operating. 1. Loosen the bottom screws that secure the clutch cover. Allow the water to drain.

Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below.

MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 2. Follow the right-hand breather line out the side of the air box and locate the filter. 3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for...

Carburetor The idle speed adjustment should be performed as outlined in the Peri- odic Maintenance Chart, or whenever the idle speed is changed. Recom- mended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted with the following procedure.

MAINTENANCE Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Always check the pedal for free movement and return before starting the engine and occasionally during operation.

Throttle System Throttle Freeplay Adjustment 1. Remove the seat. 2. Locate the throttle cable adjuster. 3. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 4. Loosen the adjuster lock nut.

Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 30. Brake Fluid Inspect the brake system rou- tinely. Inspect the level of the brake fluid before each opera- tion.

4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an autho- rized Polaris dealer. Suspension Adjustment The rear suspension may be adjusted to provide a stiffer suspension if necessary.

If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer. The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driv- ing.

Tires Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury.

Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the park brake.

Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3.

Lights Brake Lights When the brake pedal is depressed, the console brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position. 2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel.

MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion.

MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 94 before installing the battery.

See page 94. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 91. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

• Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned.

Make any necessary repairs and clean the vehicle as recommended. See page 96. Stabilize the Fuel 1. Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.

33. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death.

Dry out the PVT. See page 73. Inspect clutch seals for damage if repeated leaking occurs. See your Polaris dealer. Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).

ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.

HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registra- tion form to the dealer.

Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

Manufacturer's Warranty Coverage: The 2005 and later LSI engines are warranted for two (2) years. If any emission related part on your LSI engine is defective, the part will be repaired or replaced by POLARIS. Owner's Warranty Responsibilities: • As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's...

California Emission Control Warranty Statement Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1) has been designed, built, and equipped at the time of manufacture so as to conform with...

(iii) Filter lock assy (gaseous fuel, if applicable) If an authorized dealer determines that other LSI engine components have been dam- aged due to the failure of a warranted emission-related part during the warranty period, POLARIS will repair and/or replace the necessary components.

When the LSI engine is being serviced under warranty, POLARIS and any of its autho- rized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.

More often under severe use, such as dirty or wet conditions. Due to the nature of these adjustments, it is recommended that an authorized Polaris dealer perform service. Do not attempt to perform this work unless you are familiar with mechanical repair.

All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS. In the event that any emis- sion-related part is found to be defective during the warranty period, you must notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of the appro- priate dealer where the warranty repair is to be performed.